Wall structure



May'ZZ, 1934. J. E. D. SAYLER WALL STRUCTURE.

Filed Ma 4, 1932 WFM J 3 Sheets-Sheet I mvgm'on May 22, 1934. J. E. D.SAYLER WALL STRUCTURE Filed May 4, 1932 s Shets-Sheet 2 INVENIII'OR May22, 1934.

J. E. D. SAYLER WALL STRUCTURE Filed May 4, 1932 3 Sheets-Sheet 3Patented May 22, 1934 1,959,766 WALL STRUCTURE John Elliott DanielSayler, Pittsburgh, Pa., as-

signor to Blaw-Knox Company, Pittsburgh, Pa., a corporation ofPennsylvania Application May 4, 1932, Serial No. 609,052

4 Claims.

This invention relates to an improved wall unit and the wall constructedtherefrom.-

The wall units may comprise an outer sheet, an inner sheet, and fillermaterial interposed between the sheets. The outer sheet which comes incontact with the elements, and is, therefore, most likely to becomecorroded, is, in accordance with my invention, imperforate. The innersheet is held to the outer sheet in a manner which will be clearlypointed out in the ensuing description and set forth in the appendedclaims. In the drawings, in which certain modifications of my inventionare shown,

Fig. 1 is a horizontal sectional view, the section 'being taken througha wall constructed in accordance with my invention;

Fig. 2 is a plan view of the inner sheetof a wall unit to be made inaccordance with my invention;

Fig. 3 is a sectional view through an inner' sheet of a .wall unit withthe edge portions bent to enclose the filler material;

Fig. 4 is a sectional view at right angles to Fig. 3;

Fig. 5 is a horizontal sectional view on an enlarged scale of the wallconstruction shown in Fig. 1, this figure showing details of theinvention;

Fig. 6 is a vertical section on line VI-VI of Fig. 5;

Fig. 7 is'a vertical sectional view through the sill of a wallcomprising a unit constructed in' accordance with my invention;

Fig. 8 is a view .similar to Fig. '7 showing a modified arrangement forsecuring a wall. unit to the sill; Fig. 9 is a verticalsectional viewillustrating the eave construction of a building, together with amodified construction for securing a unit to the sill of the building;

Fig. 10 is a detail sectional view showing a unit reinforced by alongitudinal girt;

Fig. 11 is a horizontal section illustrating a construction similar tothat shown in Fig. 10 but having a screw projecting through the fillerma terial; and I Fig. 12 is a schematic sectional view illustrating themanner of anchoring a unit to the sill of the building. This view istaken on line XII-XII of Fig. 9 with the grouting removed.

In employing the term wall in the present application, this term is usedbroadly to include side or top walls; as my improved unit may beemployed for any wall of a building, including the roof or ceiling. Theunit is, as has been previously stated, made up of two sheets 'with afiller between the same. In Fig. 2, I have illustrated'the inner sheet15 as it is stamped out of a sheet of metal. The corners are indented,as show: at 16, so that the edge portions may be 60 bent outwardly toform the box-like container shown in Figs. 3 and 4. 'I'he'longer edgepor-. tions 1'7 are directed outwardly at right angles to the sheet,while the end portions 18 are first bent outwardly andthen intoparallelism with the main portion of the sheet 15 6 Into this box-likecontainer is inserted filler material 20, which may be in the form of apanel, such as a sheet or the like. This material is preferably heatinsulating in its efiect, so that heat is not readily transferredthrough the unit. This filler material may be a felted sheet of fibrousmaterial, or may be loose material packed within the box-like containershown empty in Figs. 3 and 4.

The outer metal sheet 21 is, as has been previously mentioned,imperforate. One or more corrugations 22 is formed in the sheet 21, butone corrugation being shownin the embodiment illustrated in Fig. 5,althoughit will be understood that a plurality of such corrugations may30 be provided. These corrugations have vas their function not only tostiffen the outer metal sheet 21, but also to permit a screw 24 to bepassed through the inner sheet and the filler material 20, the.corrugation 22 enclosing a space into 5 which the tip of the screw 24will project.

As has been above mentioned, the filler material 20 may be of varioustypes; and with some types, the panel of material will be strong enoughto hold the threads on the screw 24. With other types of material, Ihavefound it expedient to place a bridge member 26 over the corrugation, inthe manner illustrated in Fig. 5. These bridge members may extend theentire length of the corrugation, or may be suflicient in extent only tomake provision for receiving the screws 24. If desired, this member 26may also be of metal, and may be soldered to the sheet 21. The screw 24may pass through the member 26, as shown in. Fig. 5, or may stop shortthereof in the manner 1 0 shown in Fig. 10.

The holes for receiving the screws or other securing means may bedrilled at anytime that this is found convenient; but I prefer that theholes be drilled through the inner sheet and the 5 panel of fillermaterial after the assembling of the parts. The screw may then beinserted and tightened up to clamp the sheets to the filler material.

The edge portions of the sheet 21 at the sides 1 I of the unit arecurled over or rolled, as shown at 28. A coupling 30 is used to connectadjacent units, this coupling 30 having inwardly curled or rolledportions 31 which interlock with the rolled edge portions 28 of adjacentunits. It will be apparent, therefore, that my improved unit isstandard; and that by means of the couplings 30, as many units asdesired may be secured together to form a wall of the desired length.

It is desirable, although not necessary, that ner and outer sheetsfirmly assembled with the the parts of my improved wall unit beassembled at the factory, the filler material 20 being inserted in thereceptacle-like inner sheet 15, and the outer sheet 21 being insertedwithin the edge portions 17 of the inner sheet. To prevent displacing of(the outer sheet 21 and to hold the infiller material interposed betweenthe same, I have provided means for securing the edge portion 17 to thecurled edge portions 28 of the outer sheet 21. The securing of the edgeportions 17 may be effected in various ways, but for simplicity andexcellence of product, I prefer to crimp the edges 17 in the mannerillustrated in Figs. 5 and 9. When the inner and outer sheets have beenassembled, the edge portions 17 may be hammered over so as to somewhatclamp around the curled edge portions 28. The entire edge portions 17may be hammered over, if this is found suitable to the particular need;but for most purposes, I prefer to hammer over the edge portions 17 onlyat intervals, as illustrated in Fig. 9. Such crimping of the edgeportions 17 holds the inner and outer sheets firmly assembled with thefiller material; and when a unit is erected as a part of a building, theflanges are so clamped in position as to additionally secure the outerand inner sheets together. If it is desired that the outer and innersheets be even more securely held together, the flanges 18 may besoldered to the opposite sheet of the unit.

The edge portions 18 are adapted to engage the foundation of thebuilding, and may also be connected to the eave construction thereof.The customary wall height of small buildings does not exceed twelvefeet; and it is convenient to make units in accordance with my inventionso that they are of the full wall height. If, however, the wall heightof the building is to he, say, eighteen feet, it would usually be foundpreferable to make the units of such size that two units would beerected in superposed relation to form the wall.

As illustrated in Fig. 7, the foundation includes a sill angle ironmounted on cement work 36 by means of grouting 37. v A bolt 38 passesthrough the angle 35, was to clamp thereto the edge portion 18 of thewall unit. A strap may be employed in cooperation with adjacent units tosecure the same to the foundation 36. In Fig. 8, this strap 39 is longenough merely to be connected to the sill angle iron 35. In the formillustrated in Fig. 9, the corresponding strap 40 is long enough so thatit may be secured to-the angle iron 35, and may also be secured to abolt 41 embedded in the foundation 36. As shown in Fig. 12, the straps39 and 40 are notched at 44 and 45 on opposed sides thereof, so as toreceive the adjacentedges of the adjoining wall units. Where, as shownin Fig. 12, the adjacent edges of the units are rounded, these notches44 and 45 will 1 be rounded.

of the adjoining units. In the embodiment shown in Fig. 8, the strap 39is fastened by a screw 47 with but the angle iron 35. In the embodimentshown in Fig. 9, the strap 40 is first directed downwardly along theangle iron 35, 8 and is then directed horizontally across the foundation36. A screw 47 secures the strap 40 to the angle iron 35, and a nut 48secures the strap to the bolt 41 embedded in the foundation 36. Incertain instances, it may be found desirable to further stiffen the wallunits longitudinally;

- and in such cases, I provide a girt 49 in the form of a. structuralsteel angle held to the sheet 15 by screws 24.

The eave construction shown in Fig. 9 includes the usual eave struts 51,as well as the usual eave fiashings 52 and sheet fiashings 53.

My improved wall unit is assembled without extending securing means ofany type through the outer sheet of the building. Perforations in metalsheets, for the sake of bolting or otherwise securing the partstogether, are liable to rust at the point where the perforation is made.Leakage ensues, and the life of the structure is accordingly shortened.The corrugated outer sheet, 13. which is exposed to the weather, isimperforate, and, therefore, the several parts of the wall unit,including the screw, are protected, and the danger of corrosion ismaterially lessened.

Soldering of the bridge members to the outer sheets adds considerably tothe stiffness of the outer sheets. These bridge members permit clampingof the inner sheet to the filler material; and where the bridge membersare soldered to the outer sheet, these members permit the inner andouter sheets to be secured together in this fashion. 1

While I have illustrated and described certain preferred embodiments ofmy invention, it will be understood, however, that it is not limited tothe form shown, but may be otherwise embodied within the scope of thefollowing claims.

I claim: e

1. A wall unit comprising filler material inter posed between animperforate outer metal sheet and an inner metal sheet, the outer metalsheet having a corrugation, and securing means extending through theinner metal sheet and embedded in the filler material, the corrugationof the outer metal sheet overlying the extremity of said securing means.

2. A wall unit comprising filler material interposed between an innermetal sheet and an outer metal sheet, the" outer metal sheet having acorrugation, a member within the outer sheet bridging the corrugation,and means passing through the filler material for securing said innermetal sheet to said member.

3. A wall unit comprising filler material interposed between metalsheets and a threaded element for uniting one of said sheets with thefiller material, the other metal sheet having a corrugation overlyingthe end of the threaded element.

4. A wall unit comprising filler material interposed between an innermetal sheet and an outer metal sheet, the outer metal sheet having acorrugation, a strip within the outer sheet bridging

